Design and Losses Analysis of a High Power Density Machine for Flooded Pump Applications

Abstract

Abstract-This paper describes the design process of a 10 kW 19000 rpm high power density surface mounted permanent magnet synchronous machine for a directly coupled pump application. In order to meet the required specifications, a compact machine, with cooling channels inside the slots and flooded airgap, has been designed through finite element optimization. For high power density, high speed machines, an accurate evaluation of the power losses and the electromechanical performance is always extremely challenging. In this case, the completely flooded application adds to the general complexity. Therefore this paper deals with a detailed losses analysis (copper, core, eddy current and mechanical losses) considering several operating conditions. The experimental measurements of AC copper losses as well as the material properties (BH curve and specific core losses), including the manufacturing process effect on the stator core, are presented. Accurate 3D finite element models and computational fluid dynamics analysis have been used to determine the eddy current losses in the rotor and windage losses respectively. Based on these detailed analysis, the no load and full load performance are evaluated. The experimental results, on the manufactured prototype, are finally presented to validate the machine design.Index Terms-High power density, high speed, losses calculation, performance analysis, permanent magnet motors.

The Rebirth of the Current Source Inverter: Advantages for Aerospace Motor Design

“…180 eDeg), bringing a continuous PMs arc over the rotor (shaft) surface, and thus minimizing single stress-points over the retaining sleeve [15]. For cutting-down the rotor losses caused by eddy effect, the PMs are axially and radially segmented [18]. Additionally, they are parallel magnetised for having a sinusoidal airgap magnetic field and improving (reducing) the BEMF THD and torque ripple.…”

Optimization and Analysis of a High Power Density and Fault Tolerant Starter–Generator for Aircraft Application

“…It is worth highlighting that the specific power density of the former machine is 33 kW/L or 16 kW/kg. Similarly, a high power density PM electrical machine has been designed for flooded pump applications, with a cooling design for winding and rotor to maintain current density at 27.2 A/mm 2 [6].…”

Improving Performance and Extending Lifetime of PMSMs via Advanced End-Winding Cooling

“…The ever increasing trend towards green transportation is driven by the transition to a post-carbon economy and the leading sectors in such paradigm shift are both aerospace and automotive fields [1][2][3]. In this scenario, several highly populated cities are recently switching to electrified public road transport [4].…”